Improvement of overall performance by implementation of different lean tools - a case study

摘要

© 2021 Totem Publishers Ltd. All rights reserved.Manufacturing enhancement is a core strategy to obtain manufacturing excellence and is necessary to obtain a good financial and operational performance of small and medium scale manufacturing industries. Lean engineering tools help in reducing unwanted wastes and cycle times and also in identifying the proper alternative layout in the industry. The objective of this research is to study and identify the time taken and bottleneck stations for manufacturing the product. The bottleneck process has been addressed using line balancing which includes work load leveling. The line balancing results by distributing the workload and the result has been reached to 97 effective use of workers. 5S auditing and implementation was carried out for effective housekeeping and the scores before and after implementations were 2.54 and 3.54 respectively. The layout of the industry was analyzed and found that the current layout has more unwanted transportation, improper communication between necessary departments, and more cycle time for producing a product. The layout has been optimized and the best alternative was selected. From the simulation study, it inferred that the total cycle time was reduced by about 155 minutes and the value added time was reduced from 534 to 378 minutes.